MPC 6500 7500 Blowing toner

[jaredfmn]

I am a service rep at a dealer in Minneapolis and we have several brand new machines that blow toner all over. Meaning the dev lip fills up and starts dumping inside the machine and all over the ITB, it also cause charge rollers to have lines extremely early. It mostly does it with Cyan, but Magenta and Yellow are just as bad. List of things we have tried below:
1) Entire PCU/DEV Assemblies
2) New Developer
3)New ITB Assembly
4) Nvram
5) Hard drives
6) Drum ground in Rear Drive of Machine

Note: There really is no rythme or reason these machines are doing this. Double Double checked Sp's. I would have to say out of the 35 machines we have maybe 5 are running as clean as the 3260 5560. Any help would be greatly appreciated.

Thanks

[knightfall]

did someone do a nvram clear prior to you having the developer dump? if so when it was done or when you replaced the developer units did you enter the new TD sensor factory data on the developer units to sp3010 - 1 thru 4, 3011 - 1 thru 4, 3012 - 1 thru 4 and 3013 - 1 thru 4 without it toner dusting and dropping will occur, I also didn't see any mention of updating the firmware may want to add that as well it couldn't hurt. Good luck.

[Herrmann]

Just a shot in the dark: sticky clutches at the toner assy?

[msaeger]

Ikon or Metro ?

The only fix I have seen recommended is in bulletin 66. They say to replace the lube supply blade and to clean the charge roller. There are also several bulletins saying improper initialization at setup causes toner dusting.

[paperclipsandbubblegum]

This has been an ongoing issue for me for over a year now. I submitted an e-alert 6 months ago but a new bulletin has just been released and there may be something there. I've always maintained that these machines perform poorly in low humidity environments and this bulletin seems to address this.

[Shadow1]

I see this a lot because too much developer is being dumped from the overflow system. In theory, developer would only spill from the overflow once it reached a certain level in the unit as part of the trickle feed from the toner - in reality developer is constantly "splashing" up onto the overflow auger, and especially in low density/low toner usage conditions can easily wash too much out of the machine... which results in a light copy... which results in the machine adding much more toner... which it promptly pukes all over the inside of the machine since there is not enough developer to hold on to it.

The solution is to deactivate the overflow auger by removing the cam lever and 1 way bearing from the front of the developer unit. It appears vibration alone is enough to purge the excess developer, because I've modified several problem machines, and not a single one has given me a problem again, nor have they overfilled and bound up. I've only done this to machines I've had problems with (which is most all of them) so I don't know if it would be a good idea to recommend it as a field mod for all machines, but I've had other techs tell me they do it to all their machines with good results.

[msaeger]

I see this a lot because too much developer is being dumped from the overflow system. In theory, developer would only spill from the overflow once it reached a certain level in the unit as part of the trickle feed from the toner - in reality developer is constantly "splashing" up onto the overflow auger, and especially in low density/low toner usage conditions can easily wash too much out of the machine... which results in a light copy... which results in the machine adding much more toner... which it promptly pukes all over the inside of the machine since there is not enough developer to hold on to it.

The solution is to deactivate the overflow auger by removing the cam lever and 1 way bearing from the front of the developer unit. It appears vibration alone is enough to purge the excess developer, because I've modified several problem machines, and not a single one has given me a problem again, nor have they overfilled and bound up. I've only done this to machines I've had problems with (which is most all of them) so I don't know if it would be a good idea to recommend it as a field mod for all machines, but I've had other techs tell me they do it to all their machines with good results.

So does doing this help with the lines on the charge rollers ? That is the only problem I see really.

[turbojetboy]

So does doing this help with the lines on the charge rollers ? That is the only problem I see really.

We find we have to change the charge rollers endlessly, they often only make around 10k - from new! You have no choice but to change them, I carry 3 full sets of them and wont walk into one of these dogs without them.

[Shadow1]

So does doing this help with the lines on the charge rollers ? That is the only problem I see really.

Nope. I'm afraid the only thing that's going to stop that is explosives.

O.K. not really, but I've been tempted. Actually, I've been experimenting with leaving the springs off the lube bar assy, or leaving the lube bar out completely. Problem is, both my experiment machines are no longer in the field - one was upgraded to a C900, the other was returned.

[msaeger]

I had one took the lube bar out of the cyan on and stopped getting the lines on the charge roller. So then I tried taking them all out on a different one and the drums did get wrecked. I haven't tried taking the springs off or using different springs yet.

[Wishbone]

These machines blow in more ways than one!

[stephend]

I am a service rep at a dealer in Minneapolis and we have several brand new machines that blow toner all over. Meaning the dev lip fills up and starts dumping inside the machine and all over the ITB, it also cause charge rollers to have lines extremely early. It mostly does it with Cyan, but Magenta and Yellow are just as bad. List of things we have tried below:
1) Entire PCU/DEV Assemblies
2) New Developer
3)New ITB Assembly
4) Nvram
5) Hard drives
6) Drum ground in Rear Drive of Machine

Note: There really is no rythme or reason these machines are doing this. Double Double checked Sp's. I would have to say out of the 35 machines we have maybe 5 are running as clean as the 3260 5560. Any help would be greatly appreciated.

Thanks

We are fighting with the same same problem here in Calgary, Canada. We have tons of problems all over the city with identical symptoms.
New Jersey and Toronto tech support centers are no ready to recognize that it's a problem with these machine (a big one). After many hours of continuous analysis of SMC reports I can tell you that all the affected units have in common one thing:Humidity. In all the cases the humidity was less than 15%...so out of the operational range of the machine. Neither at 15% RH you won't see any improvements. Spoke with other techs in more humid locations and they are saying that it's not so bad...so humidity plays (I think) a huge role in our problems.
With this occasion I want to ask you guys to post together with your problem...the humidity recorded at the machine level and at the PCU level...at least to have a better idea of what is going on in different places
To check humidity level: SP 2302 (machine level) and SP 2901 (PCU level)

[stephend]

I see this a lot because too much developer is being dumped from the overflow system. In theory, developer would only spill from the overflow once it reached a certain level in the unit as part of the trickle feed from the toner - in reality developer is constantly "splashing" up onto the overflow auger, and especially in low density/low toner usage conditions can easily wash too much out of the machine... which results in a light copy... which results in the machine adding much more toner... which it promptly pukes all over the inside of the machine since there is not enough developer to hold on to it.

The solution is to deactivate the overflow auger by removing the cam lever and 1 way bearing from the front of the developer unit. It appears vibration alone is enough to purge the excess developer, because I've modified several problem machines, and not a single one has given me a problem again, nor have they overfilled and bound up. I've only done this to machines I've had problems with (which is most all of them) so I don't know if it would be a good idea to recommend it as a field mod for all machines, but I've had other techs tell me they do it to all their machines with good results.

I presented exactly the same theory to one of our trainers and he told me that is "out of discussion" ) His opinion is that the ID sensors especially for Cyan and Magenta are faulty ?????
Recently I had one issue with a machine that performed well for a a full month after a full PM (with new units) was done...and exactly after 1 month the K unit start giving them light prints....all the color units were OK. I tested the toner supply system by adding toner (big mistake....) and for the moment the situation was fixed. The machine start working fine...for another day. The second day customer called again and told me that the K unit "exploded"...When I arrived I was able to see a massive toner spill from the K unit...blotches after blotches....so I think the TD sensor start acting weird....A brand new unit and a new bag of developer saved the day...if you can call it like this.
Lube bar cleaning blade it has nothing to do with this behavior...Personally I think this one is responsible for the lines on the charge rollers so at every call for lines am cleaning them and vacuum all the excess lube/toner behind it

[salesux]

Glad to see I'm not the only one with this issue. That's what tech support in NJ told me. They recommended I change the toner supply units and transfer rollers??? Toner supply units maybe. Except when a machine has this issue its always with CMY not K. And Cyan is always the worst. So just the CMY toner supply units go bad? I have had this issue from the moment I first saw a unit in this series. I believe I've tried everything I can think of. I have 30 to 40 of these units and I can't see a pattern. I've collected SMC reports from most of them and there isn't a difference that I can see when they dump. And when they stop dumping they run fine for awhile. Anyway I'm glad to see I'm not the only one frustrated with these units.

[stephend]

Yes, Cyan is the worst one AND IS DUMPING starting with the first print/copy you made...I saw machines with 20K with PTR area full of cyan...it's all over...the vacuum transport and over the fuser, in the transfer belt unit...To replace the toner supply units will make sens if will be only one machine with this problem...but everybody is complaining about same thing....so all the toner supply units are defective???? Transfer rollers no success...I replaced them with the new part number and no improvement... The only improvement that make sens is to take out the cam that is moving the overflow auger...

Today I preflighted the first MPC 6501. I will be the first happy camper to service one of those....It look like they changed something...I'll try determine fast what and maybe we can find a way to improve the MPC 6000's or the Pro 550's.